My Moto4 project

[Gwbarm]

Doing a great job ,almost got it ready, good work, another one saved from the junk yard. I would still fix the choke plunger you will need it on a cold engine. Use a combination of PB Blaster and carb cleaner and soak it down really good it will come out.

[Mech]

Yup, and if you gently tap the aluminium on the side of the plunger it might help the oil creep in.

[tin]

I've tried all sorts of things to free it. Not necessarily in this order... Carb cleaner, WD40, acetone, heating it, hitting it, pushing it down with a screwdriver. It did have 20 years to get itself stuck 🤣

I'm considering chopping the cable and getting better access to it that way. But I'll be leaving it until I've got things like tyres and brakes done. It's low on the priority list at the moment.

[Mech]

They will generally turn easier than pull out. What you need is a modified screwdriver. The plunger metal is soft and if you use a regular screwdriver it will spread the plunger and make it jam. Get a screwdriver that has a tip the thickness of that slot, it will be too wide to go in but you should be able to move the cable to one side, then grind the width of the screwdriver down so it's going to fit down beside the cable, then, carefully grind the flat of the screwdriver so it is concave and the tip is the thickest bit. You need to grind it a long way back so that the tip can go right to the bottom of the slot. Then, because the tip is putting the force on right at the bottom of the slot, you can apply quite a bit of force. Get it turning and turn it till it turns easily, then start pulling up gently while you turn it. The slots will grind the gunge away and it will slowly come up. If it gets tight, push it down and lube it plenty with runny oil to flush the gunge away then keep turning and pulling. I've got plenty out like that. 

Make sure you've ground the screwdriver enough that it's only touching at the bottom of the slot..

[toe420]

Good job on getting it going. I just got 2 moto 4 225cc quads im hoping to get running again.